Salzgitter Supply Chain Concept for Industrial Assembling of Offshore-Wind-Jackets
Verbesserung der Wettbewerbsfähigkeit von Jackets durch innovative Fertigungsstrategien
Increasing competitiveness of Jackets by innovative manufacturing strategies
Dr. S. Brauser / Salzgitter Mannesmann Renewables
Dr. M. Los / St3 Offshore
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Agenda
1 Salzgitter Group
2 Salzgitter Supply Chain Concept
3 Serial manufacturing of Jackets
� Robotized welding of nodes
� Robotized grinding of nodes
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Company portfolio
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Salzgitter Group
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Steel and Technology Line pipes
Precision tubes
Stainless tubes
Stockholding trading
International trading
Strip products
Steel Service Center
Heavy plates
Sections
Engineering services
Injection molding machinery Beverage filling plants
• Crude steel production 2014: 7.3 million tons; trading volume: 5.1 million tons • External Sales cons.: 9.0 € billion / Employees: 23,555
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Company portfolio - Penetration Offshore Wind
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Salzgitter Group
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Steel and Technology Line pipes
Precision tubes
Stainless tubes
Stockholding trading
International trading
Strip products
Steel Service Center
Heavy plates
Sections
Engineering services
Injection molding machinery Beverage filling plants
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Competitive edge of Offshore Wind Tubular Companies with Bilfinger Cooperation
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� Salzgitter Flachstahl: Base material for HFI
and Spiral tubes
� Mannesmann Grobblech
� Ilsenburg Grobblech
Base material for Monopiles and large diameter tubes
� Europipe: LSAW pipes up to OD 1524/ wt 50mm (marked leader)
� MLP: HFI pipes up to OD 610 / wt 25.4mm
� SMGR: Spiral pipes up to OD 1676 / wt 25.4mm
Strip Steel Plate / Section Steel Tube
St3 Offshore
Salzgitter Offshore Wind Expertise Cooperation
� Combined Development of � modular Jacket design and secondary ° steel system � Robotized welding of nodes
� Combined market approach � Complete foundation structure ° including TP will be market by BMO � Jacket components such as nodes ° and pipes will be market by Salzgitter
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Salzgitter supply chain � Supply of component kid composed of
• Standardized tubes • K, Y, X- nodes • Sections / frames • …
� Jackets can be build out of sections, or from components at a site or port local to a wind farm
� Applicable for all Jacket fabricators and without any design preferences
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Agenda
1 Salzgitter Group
2 Salzgitter Supply Chain Concept
3 Serial manufacturing of Jackets
� Robotized welding of nodes
� Robotized grinding of nodes
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Serial manufacturing of Jackets
Standardized tube • Based on pipeline application • Fully automated welding and NDT • High productivity (up to 200 pipes / shift) • Low geometrical tolerances Æ reduction in welding / assembling time • High cost competitiveness against JCO pipes Æ 20% to 30%
Robotized welding of nodes • Tubular welds are cost driver ..within jacket manufacturing • Robotized welding of nodes ..leads to: o acceleration within …production o uniform weld properties o improvement of fatigue by …inside welding and optimized …weld shape
Assembly of components by orbital welding • Cost efficient welding of butt joints • Significant reduction in cost/time compared to manual welding
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Automated fabrication of nodes – general approach
Manipulator
Welding torch
Robot uni
� Replacement of manual welding by
robots Æ reduction in welding time and cost
Æ sustainable quality improvements by controlled processes (heat input, weld profile)
Æ efficient inside welding
� Welding of stubs onto chord by • Manipulator:
Movement of node enables welding always in 1G/PA Position Æ high welding speed, lower
welding defect rate • Robot unit:
Utilization of high productive tandem-welding
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Pre-fabrication of nodes – general approach
1) Semi-automatic loading of chord / stubs
2) Manual tack welding
3) Pre-heating + Robotized inside root welding Æ backing layer
4) Outside welding
First outside layer (hot pass) to be carried out with sufficiently high energy to guarantee:
• full penetration weld • prevention of root failure
• Filling passes with high deposition rate • Cap layer with oscillated welding head to generate smooth weld profile
Loading of the main pipe Automatic positioning + tack welding of stub
Tack welding
Inside welding
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Further Potentials – under investigation
� Optimization of weld geometry / notch effect • Reliable modeling of weld geometry such that
• smooth transition tangent to the parent material Æ negligible notch effect / fatigue improved
• Monitoring /memorizing of surface notches / weld profile via camera system for each stub
� Inside welding of nodes (applicable) • Currently not used for Jacket manufacturing do
to point to point approach
• Robotized pre-fabrication of nodes enables efficient inside welding
• Improvement of fatigue strength especially when outside weld profile / notch effect is improved
• Backing layer: guarantee of full penetration weld
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Weight reduction due to smooth shape of welds
page 16 Bilfinger Mars Offshore sp. z o.o.
Smooth shape - Stress distribution due to out of plane moment
Normal weld shape - Stress distribution due to out of plane moment
Improved weld shape
� leads to a damage reduction by factor 1,77÷1,96 . � Weight reduction of 5÷10 % for whole primary steel
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Weld toe grinding
� Local grinding of the weld toes below any visible undercuts increase fatigue life significant
� The grinding depth should not exceed 2 mm or 7% of the plate thickness, whichever is smaller
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Automated weld toe grinding – feasibility
3D Profil-Scan
I. Robotized welding of node
II. Extraction of samples
III. 3D Profil Scan
IV. Derive of Track Curve
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V. Automated grinding of nodes segment
� Next Steps
• Calculation of mass reduction of Jacket based on DNVGL rules
• Full Scale node grinding test